Method and apparatus for aligning a wind turbine generator

ABSTRACT

A method and apparatus for aligning an input shaft of a wind turbine generator with an output shaft of a wind turbine are disclosed. Preferably, the method includes placing a push plate of a wind turbine alignment tool into pressing contact with a selected support flange of a wind turbine generator identified by a misalignment measurement device. With the push plate positioned, an indexing means of the wind turbine alignment tool is advanced along an adjustment link member of the wind turbine alignment tool to impart an alignment force onto the selected support flange to align the input shaft of the wind turbine generator with the output shaft of the wind turbine. The method preferably concludes by rechecking the alignment of the input shaft of the wind turbine generator with the output shaft of the wind turbine.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of copending U.S. patentapplication Ser. No. 13/493,868 filed Jun. 11, 2012, which is acontinuation of U.S. Pat. No. 8,196,304 issued Jun. 12, 2012, whichclaims the benefit of priority to and is a Patent Application of U.S.Provisional Patent Application Ser. No. 61/095,520, entitled “Method ForAligning A Wind Turbine Generator,” filed Sep. 9, 2008. Theaforementioned provisional patent application has not been assigned andthe ownership resides solely with the inventor, and the entirety of theaforementioned patent application is incorporated herein by referencefor all purposes.

FIELD OF THE INVENTION

This invention relates to new and useful improvements in wind turbinegenerator maintenance. In particular, but not by way of limitation,those improvements relate to a method and apparatus for aligning aninput shaft of a wind turbine generator with a corresponding outputshaft of a wind turbine.

BACKGROUND

Wind turbine generators for generating electric power using wind power,which is a natural form of energy, are known. Such a wind turbinegenerator includes a nacelle disposed on a tower. The nacelle includes arotor head equipped with blades, a main shaft connected to the rotorhead so as to integrally rotate with the rotor head, a gearbox connectedto the main shaft that rotates upon receiving the wind power supplied tothe blades, and a generator driven by a shaft output from the gearbox.According to the wind turbine generator having this structure, the rotorhead is equipped with the blades which convert wind power into arotational force, and the main shaft rotates to generate a shaft output.The rotational speed is increased via the gearbox connected to the mainshaft and the resulting shaft output is transmitted to the generator.Consequently, the shaft output obtained by converting the wind powerinto the rotational force is used as a driving source of the generator,and thus power generation can be performed using the wind power asmotive power for the generator.

Since recent wind turbine generators tend to increase their output byincreasing the size thereof, the sizes of components such as the rotorhead, the main shaft, the gearbox, and the generator also increase,resulting in an increase in weight, and an increase in the need toassure alignment between the gearbox shaft and the generator main shaft.Misalignment can lead to premature and costly failures of the system, aswell as loss in income due to the inability to generate energy.

Accordingly, as market pressures continue to demand wind turbine systemsthat provide lower cost, greater reliability, and longer service lives,challenges remain and a need persists for improvements in methods andapparatuses for use in the maintenance of wind turbine systems.

SUMMARY OF THE INVENTION

In accordance with an embodiment, a method of aligning an input shaft ofa wind turbine generator with an output shaft of a wind turbine isprovided. Preferably, the method includes the steps of placing a pushplate of a wind turbine alignment tool into pressing contact with aselected support flange of a plurality of support flanges of the windturbine generator. Preferably, the selected support flange is selectedbased on misalignment data provided by a misalignment measurementdevice. The steps further preferably include advancing an indexing meansof the wind turbine alignment tool along an adjustment link member ofthe wind turbine alignment tool to impart an alignment force onto theselected support flange to align the input shaft of the wind turbinegenerator with the output shaft of the wind turbine. The embodimentpreferably concludes by rechecking the alignment of the input shaft ofthe wind turbine generator with the output shaft of the wind turbine toascertain whether further alignment between the input shaft of the windturbine generator and the output shaft of the wind turbine is required.

These and various other features and advantages that characterize theclaimed invention will be apparent upon reading the following detaileddescription and upon review of the associated drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a front perspective view of a preferred embodiment of theinventive wind turbine generator alignment tool.

FIG. 2 shows a top plan view of an end effector of the inventive windturbine generator alignment tool of FIG. 1.

FIG. 3 shows a bottom plan view of the end effector of the inventivewind turbine generator alignment tool of FIG. 1.

FIG. 4 shows an end view in elevation of the end effector of theinventive wind turbine generator alignment tool of FIG. 1.

FIG. 5 shows a cross section view in elevation of the end effector ofthe inventive wind turbine generator alignment tool of FIG. 1.

FIG. 6 shows a cross-section side elevation view in partial cutaway ofan alignment mechanism that includes an alignment link communicatingwith an indexing means adjacent a force distribution means of theinventive wind turbine generator alignment tool of FIG. 1.

FIG. 7 shows an end view in elevation of the indexing means of FIG. 6.

FIG. 8 shows an end view in elevation of the force distribution means ofFIG. 6.

FIG. 9 shows a side elevation view in partial cutaway of a preferredembodiment wind turbine generator with a misalignment measurement deviceattached thereto.

FIG. 10 shows a side elevation view of the inventive wind turbinegenerator alignment tool of FIG. 1 mounted in an operative positionadjacent a wind turbine generator.

FIG. 11 shows a flowchart of a method of using the inventive windturbine generator alignment tool of FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to one or more examples of theinvention depicted in the figures. Each example is provided by way ofexplanation of the invention, and not meant as a limitation of theinvention. For example, features illustrated or described as part of oneembodiment may be used with another embodiment to yield still adifferent embodiment. Other modifications and variations to thedescribed embodiments are also contemplated within the scope and spiritof the invention.

Referring to the drawings, FIG. 1 shows a preferred embodiment of aninventive wind turbine generator alignment tool 100 that includes a pushplate 102, also referred to herein as a force displacement structure102, formed by a pair of push rails 104 secured to a force displacementplate 106, also referred to herein as a main body portion 106, an endeffector 108 interacting with a link member 110, which passes through anengagement aperture 112 of the force displacement plate 106. Thepreferred embodiment of the wind turbine generator alignment tool 100,when the end effector 108 is secured in its operative position, anindexing means 114 is threaded onto the link member 110, a forcedisplacement means 116 is passed over the link member 110 and intoadjacency with the indexing means 114, and the link member 110 is passedthrough the engagement aperture 112 and threaded into the end effector108.

FIGS. 2, 3, 4, and 5 collectively show a plurality of views of thepreferred end effector 108, and are best viewed collectively for anenhanced understanding of the end effector 108. Shown in dotted lines byFIG. 2 are a securement stud attachment aperture 118 and a link memberattachment aperture 120 provided by the end effector 108. FIG. 3 showsan end view of the link member aperture 120, while FIG. 4 shows a bottomview of the securement stud attachment aperture 118.

FIG. 5 shows a cross-section of the end effector 108 revealing that boththe securement stud attachment aperture 118, and the link memberaperture 120 are preferably threaded to accommodate engagement of theend effector onto a securement stud 122 (see FIG. 9), and the engagementof the link member 110. It will be noted that in a preferred embodimentof the end effector 108, the link member aperture 120 may be used tointeract with the securement stud 122, while the securement studattachment aperture 118 may be used to interact with the link member110.

FIG. 6 shows a preferred alignment mechanism 123 in cross-section thatincludes the alignment link 110 communicating with the indexing means114, which is adjacent the force distribution means 116 of the inventivewind turbine generator alignment tool 100 of FIG. 1. FIG. 7 shows theindexing means 114 in side elevational view, and FIG. 8 shows the forcedistribution means 116 in side elevational view.

Moving to FIG. 9, illustrated therein is a preferred wind poweredelectric generating system 125, which includes a wind turbine outputshaft 124 secured to a wind turbine generator input shaft 126 by aflexible coupling 128. In a preferred embodiment, a wind turbinegenerator 130 supporting the wind turbine generator input shaft 126 issecured to a generator platform 132 by a plurality of securement studs122. Preferably, a plurality of support flanges 134, corresponding toeach of the plurality of securement studs 122 are attached to thegenerator 130. Each support flange 134 is preferably isolated from thegenerator platform 132 by a corresponding isolation pad 136, and heldunder a compressive load adjacent its associated isolation pad 136 by aflange retainer 138.

During operation of the wind powered electric generating system 125,misalignment between the wind turbine output shaft 124 and the windturbine generator input shaft 126 may occur, necessitating a realignmentof the wind turbine output shaft 124 with the wind turbine generatorinput shaft 126. To determine the presence and severity of such amisalignment, a misalignment measurement device 140 is preferably used.In a preferred embodiment, the misalignment measurement device 140includes a first sensor 142, linked to a processor 144 by a firstcommunication cable 146, and a second sensor 148 linked to the processor144 by a second communication cable 150. However, those skilled in theart will understand that the communication cables 146 and 150 areprovided as one form of communication linkage between the sensors 142and 148, wireless communication between the sensors 142 and 148 and theprocessor 144 is also contemplated by the present invention.

Use of the preferred misalignment measurement device 140, entails adetermination of particular distances such as 152, taken between thefirst sensor 142 and the second sensor 148; 154, taken between thesecond sensor 148 and a first securement stud 122; and 156, takenbetween the first securement stud 122 and the second securement stud122. The angular relationship between the first and second sensors 142,148, as the sensors are rotated about the path of rotation of theflexible coupling 128, and relative to the determined distances 152,154, and 156, are used by the processor 144 to calculate the amount ofoperative misalignment when an operative misalignment is present betweenthe wind turbine output shaft 124 and the wind turbine generator inputshaft 126.

FIG. 10 depicts the flange retainer 138, backed off from the supportflange 134 in preparation for realignment of the generator 130 by theinventive wind turbine generator alignment tool 100. With the push plate102 in abutting adjacency with the flange 134, advancement of theindexing means 114 along the link member 110 translates an appliedrotational force 158 into a linear force 160, which shifts the positionof the support flange 134 relative to the securement stud 122 to alignthe wind turbine generator input shaft 126 with the wind turbine outputshaft 124 (each of FIG. 6).

Turning to FIG. 11, shown therein is a flow chart 200, which depicts amethod of utilizing an inventive wind turbine generator alignment tool(such as 100). The method commences at start process step 202 andproceeds to process step 204 with a placement of a push plate (such as102) in abutting adjacency with a predetermined generator support flange(such as 134). At process step 206, the method continues withdetermining an amount of generator misalignment, and at process step208, an alignment force (such as 160) to align a generator (such as 130)is applied to the predetermined support flange via an application of arotational force (such as 158) to an index means (such as 114) to alignan input shaft (such as 126) of a wind turbine generator (such as 130)with an output shaft (such as 124) of a wind turbine (such as 162 ofFIG. 9).

At process step 210, alignment between the generator and the windturbine is re-checked to assure alignment between the wind turbine andthe generator has been attained, relative to the support flange beingacted upon. At process step 212, the push plate is secured in abuttingadjacency with an alternate predetermined support flange. When theinventive wind turbine generator alignment tool is securely in positionadjacent the alternate predetermined support flange, a second alignmentforce (such as 160), to align the generator is applied to the alternatepredetermined support flange via an application of a second rotationalforce (such as 158) to the index means to align the input shaft of thewind turbine generator with the output shaft of the wind turbine, andthe process concludes at end process step 216.

With respect to the above description, it is to be realized that theoptimum dimensional relationships for the parts of the invention, toinclude variations in size, materials, shape, form, function and mannerof operation, assembly and use, are deemed readily apparent and obviousto one skilled in the art, and all equivalent relationships to thoseillustrated in the drawings and described in the specification areintended to be encompassed by the present invention.

It will be clear that the present invention is well adapted to attainthe ends and advantages mentioned as well as those inherent therein.While presently preferred embodiments have been described for purposesof this disclosure, numerous changes may be made which will readilysuggest themselves to those skilled in the art and which are encompassedby the appended claims.

What is claimed is:
 1. An apparatus comprising: a support flangeengaging a securement stud via a securement aperture; a forcedisplacement structure contacting the support flange; and an indexingmeans communicating with the securement stud and force displacementstructure, the indexing means configured to translate a rotational forceto linear force, the indexing means moving the support flange inrelation to the securement stud.
 2. The apparatus of claim 1, in whichthe indexing means comprises a threaded bolt, with an associatedfastener.
 3. The apparatus of claim 2, in which the associated fastenercomprises a threaded nut concurrently contacting the threaded bolt andforce displacement structure.
 4. The apparatus of claim 3, in which theindexing means comprises, an end effector communicating with thethreaded nut.
 5. The apparatus of claim 4, in which the threaded nutengages a first side of the three displacement structure, opposite theend effector.
 6. The apparatus of claim 3, in which a force displacementstructure is disposed between the threaded nut and the forcedisplacement plate.
 7. The apparatus of claim 1, in which the forcedisplacement structure comprises at least a push rail affixed to a sideof the force displacement structure.
 8. A tool comprising: a supportflange secured to a wind turbine generator, the support flange engaginga securement stud via an aperture; a force displacement structure incontact adjacency with the support flange; and an indexing meanscommunicating with the securement stud and force displacement structure,the indexing means translates a rotational force to linear force, thelinear force moves the support flange in relation to the securementstud.
 9. The tool of claim 8, in which the indexing means comprises athreaded bolt engaging the securement stud via an end effector andengaging the force displacement structure via an engagement aperture anda threaded nut.
 10. The tool of claim 9, in which the end effector hasfirst and second attachment apertures oriented orthogonal to oneanother.
 11. The tool of claim 10, in which the first and secondattachment apertures are each threaded.
 12. The tool of claim 11, inwhich the force displacement structure exclusively contacts the supportflange and indexing means.
 13. The tool of claim 8, in which the forcedisplacement structure comprises: a main body portion; and a push railsecured to the main body portion.
 14. A method by steps comprising:engaging a support flange and a securement stud via a securementaperture; contacting a force displacement plate with the support flange;attaching an indexing means to the securement stud and forcedisplacement plate; and translating a rotational force to linear forcewith the indexing means to move the support flange in relation to thesecurement stud.
 15. The method of claim 14, in which the indexing meansis translated by rotating a threaded nut secured to a threaded boltattached to both the securement stud and force displacement plate. 16.The method of claim 14, in which the force displacement plate contactsonly the support flange and securement stud during the translating step.17. The method of claim 14, in which movement of the support flangealigns an input shaft of a wind turbine generator secured to the supportflange with an output shafts of a wind turbine.
 18. An apparatus foraligning an input shaft of a wind turbine generator with an output shaftof a wind turbine comprising: a support flange secured to said windturbine generator; a push rail in contacting adjacency with the supportflange; an indexing means, the indexing means generates a rotationalforce used to align said input shaft of said wind turbine generator withsaid output shaft of said wind turbine; and a force displacementstructure disposed between the indexing means and the push rail, theforce displacement structure translates said rotational force intolinear displacement thereby aligning said input shaft of said windturbine generator with said output shad of said wind turbine.
 19. Theapparatus of claim 18, in which said push rail comprises a pair of pushrails.
 20. The apparatus of claim 18, in which said force displacementstructure provides an engagement aperture, and further comprising a linkmember interacting with said engagement aperture and communicating withsaid indexing means.